EP2207916B1 - Solvent stripping process ultilizing an antioxidant - Google Patents

Solvent stripping process ultilizing an antioxidant Download PDF

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Publication number
EP2207916B1
EP2207916B1 EP08846556.2A EP08846556A EP2207916B1 EP 2207916 B1 EP2207916 B1 EP 2207916B1 EP 08846556 A EP08846556 A EP 08846556A EP 2207916 B1 EP2207916 B1 EP 2207916B1
Authority
EP
European Patent Office
Prior art keywords
solvent
process according
antioxidant
polymer
nonwoven web
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP08846556.2A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP2207916A2 (en
Inventor
Pankaj Arora
Junaid Ahmed Siddiqui
Simon Frisk
Young H. Kim
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EIDP Inc
Original Assignee
EI Du Pont de Nemours and Co
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Publication date
Application filed by EI Du Pont de Nemours and Co filed Critical EI Du Pont de Nemours and Co
Publication of EP2207916A2 publication Critical patent/EP2207916A2/en
Application granted granted Critical
Publication of EP2207916B1 publication Critical patent/EP2207916B1/en
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Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D10/00—Physical treatment of artificial filaments or the like during manufacture, i.e. during a continuous production process before the filaments have been collected
    • D01D10/02—Heat treatment
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D10/00—Physical treatment of artificial filaments or the like during manufacture, i.e. during a continuous production process before the filaments have been collected
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • D01F1/106—Radiation shielding agents, e.g. absorbing, reflecting agents
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F13/00—Recovery of starting material, waste material or solvents during the manufacture of artificial filaments or the like
    • D01F13/04—Recovery of starting material, waste material or solvents during the manufacture of artificial filaments or the like of synthetic polymers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • D04H3/166—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion the filaments being flash-spun
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/0007—Electro-spinning
    • D01D5/0015—Electro-spinning characterised by the initial state of the material
    • D01D5/003—Electro-spinning characterised by the initial state of the material the material being a polymer solution or dispersion
    • D01D5/0038—Electro-spinning characterised by the initial state of the material the material being a polymer solution or dispersion the fibre formed by solvent evaporation, i.e. dry electro-spinning
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/60—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyamides
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
    • Y02P70/62—Manufacturing or production processes characterised by the final manufactured product related technologies for production or treatment of textile or flexible materials or products thereof, including footwear

Definitions

  • a process for stripping solvent from solvent-laden fibers in a solution-spun fiber web containing an antioxidant is disclosed.
  • the process of solution spinning involves dissolving a desired polymer into a suitable solvent, and spinning fibers from the polymer/solvent solution.
  • the solvent is an organic solvent which has undesirable properties in use of the so-formed fabric, such as adverse health effects, undesired odor and the like. It would be desirable to strip the unwanted solvent from the fibers or fabric during the production process, prior to use..
  • Solution spinning processes are frequently used to manufacture fibers and nonwoven fabrics, and in some cases have the advantage of high throughputs, such that the fibers or fabrics can be made in large, commercially viable quantities.
  • significant quantities of residual solvent can be entrained in the collected fabrics or fibers.
  • the residual solvent would merely evaporate upon sitting, leaving the fabric solvent-free, but in many cases the ideal solvent used for the solution spinning process has a high chemical or physical affinity for the fiber polymer.
  • the fiber polymer is swollen by the solvent; i.e. the solvent molecules are absorbed and dispersed within the polymeric fibers.
  • the solvent chemically bonds to the polymer molecules making up the fiber, such as by hydrogen bonding, Van der Waals forces, or even ionically via salt formation.
  • the invention is directed to a process for stripping chemically bonded spinning solvent from a solution-spun nonwoven web comprising the steps of providing a nonwoven web of solvent-laden polymeric nanofibers comprising a thermal-stabilizing effective amount of antioxidant, and heating and transporting the nonwoven web through a solvent stripping zone at a temperature and residence time sufficient to reduce the solvent concentration of the nonwoven web to less than about 1,000 ppmw.
  • the present invention relates to solvent-spun webs and fabrics for a variety of customer end-use applications, such as filtration media, battery and capacitor separators, protective apparel and the like, including at least one nanofiber layer, and a process for removing excess spinning solvent from the solution-spun nanofiber webs or fabrics.
  • solution spinning processes such as wet spinning, dry spinning, flash spinning, electrospinning and electroblowing, involve dissolving a desired polymer into a suitable solvent, and spinning fibers from the polymer/solvent solution.
  • significant quantities of residual solvent can be entrained in the collected fabrics or fibers, due to either or both of high physical or chemical affinities of the solvent for the polymer so spun, and the lack of sufficient time or space between fiber formation and fiber collection for complete evaporation of the spinning solvent.
  • the solvents used in the solution spinning processes demonstrate various levels of toxicity, or present negative environmental effects or cause adverse chemical reactions in particular end-uses. As such, it is preferred to remove as much residual solvent from the solution spun fibrous materials as possible.
  • Solvent removal is often complicated by the fact that any particular polymer/solvent spinning system is chosen based upon a strong affinity of the solvent for the polymer, in order to effect complete dissolution of the polymer in the solvent during the spinning operation.
  • the fiber polymer is swollen by the solvent; i.e. the solvent molecules are absorbed and dispersed within the polymeric fibers.
  • the solvent chemically bonds to the polymer molecules making up the fiber, such as by hydrogen bonding, Van der Waals forces, or even ionically via salt formation.
  • solution spun fibers have diameters less than about 1 micrometer (nanofibers) to optimize the diffusion de-volatilization mechanism of solvent removal.
  • nanofibers refers to fibers having diameters varying from a few tens of nanometers up to several hundred nanometers, but generally less than about one micrometer, even less than about 0.8 micrometer, and even less than about 0.5 micrometer.
  • the solution spun fabrics and webs of the present invention include at least one layer of polymeric nanofibers.
  • the nanofibers have average fiber diameters of less than about 1 ⁇ m, preferably between about 0.1 ⁇ m and about 1 ⁇ m, and high enough basis weights to satisfy a variety of commercial end-uses, such as for air/liquid filtration media, battery and capacitor separators, protective apparel and the like.
  • a process for making commercial quantities and basis weights of nanofiber layer(s) is disclosed in International Publication Number WO2003/080905 ( U.S. Serial No. 10/822,325 ), which is hereby incorporated by reference.
  • This prior art electroblowing method comprises feeding a solution of a polymer in a solvent from a mixing chamber through a spinning beam into a spinning nozzle to which a high voltage is applied, while compressed gas is directed toward the polymer solution in a blowing gas stream as it exits the nozzle to form nanofibers, and collecting the nanofibers into a web on a grounded collector under vacuum.
  • the solvent stripping process In order to remove the residual solvent, the solvent stripping process often requires the use of an elevated temperature. This heating of the nonwoven web can lead to undesirable chemical and mechanical degradation of the polymer.
  • an antioxidant has been found to help retard the thermo-oxidative degradation of the fiber polymer, allowing for solvent stripping at higher temperatures, such as from greater than about 70 °C up to just below the melting point of the fiber polymer, or for a longer residence times, as compared to the maximum safe temperatures and residence times in the absence of an antioxidant. Accordingly, the presence of antioxidants helps in reducing the residual solvent to very low levels, which was not previously possible.
  • the antioxidants are mixed into the spinning solution in an amount sufficient to retard decomposition of the polymer.
  • the amount of antioxidant varies upon the efficiency of the antioxidant in retarding thermal degradation for a particular polymer, but is generally effective in the range of about 0.01 weight percent to about 5 weight percent based on the weight of the polymer or even about 0.05 weight percent to about 2 weight percent based on the weight of the polymer.
  • the antioxidant can be compounded with the polymer prior to dissolution, or even copolymerized with the polymer under certain circumstances.
  • Antioxidants that are useful for this invention include: phenolic amides such as N,N'-hexamethylene bis(3,5-di-(tert)-butyl-4-hydroxyhydrocinnamamide) (Irganox 1098); amines such as various modified benzenamines (e.g.
  • Irganox 5057 phenolic esters such as ethylenebis(oxyethylene)bis-(3-(5-tert-butyl-4-hydroxy-m-tolyl)-propionate (Irganox 245) (all available from Ciba Specialty Chemicals Corp., Tarrytown, NY); organic or inorganic salts such as mixtures of cuprous iodide, potassium iodide, and zinc salt of octadecanoic acid, available as Polyad 201 (from Ciba Specialty Chemicals Corp., Tarrytown, NY), and mixtures of cupric acetate, potassium bromide, and calcium salt of octadecanoic acid, available as Polyad 1932-41 (from Polyad Services Inc., Earth City, MO); hindered amines such as 1,3,5-triazine-2,4,6-triamine,N,N"'-[1,2-ethane-diyl-bis[[[4,6-bis-[butyl
  • antioxidants in the fibers permits the use of higher stripping temperatures and/or longer residence times in the solvent stripping zone, which can rapidly reduce the solvent concentration in the fibers to less than about 1,000 ppmw or even less than about 100 ppmw.
  • solvent stripping zones examples include zones that utilize heated gas or radiant energy, for example, infrared energy and microwave energy.
  • nonwoven web examples below were prepared according to the electroblowing method described in WO2003/080905 from a polymer solution of nylon 6, 6 polymer in formic acid solvent, with or without antioxidant to form nonwoven webs containing some residual solvent.
  • the residual formic acid content in the nonwoven sheets of nylon was determined using standard wet chemistry techniques and ion chromatography analysis. In a typical determination, a sample of known mass was placed in caustic solution. An aliquot of the resulting solution was analyzed by ion chromatography and the area under the peak corresponding to neutralized formic acid (formate anion) was proportional to the quantity of formic acid in the sample.
  • the Comparative Examples were derived from a control nonwoven web prepared as set forth above, but in the absence of an antioxidant.
  • the resulting control nonwoven web had a basis weight of 11.5 g/m 2 with fibers having an average fiber diameter of 350 nanometers.
  • the nonwoven web had a residual solvent content of 2419 ppm.
  • the master nonwoven web was transported through a solvent stripping zone at a temperature of 180°C with hot air impinging the surface of the nonwoven web for residence times of 24, 48 and 240 seconds to produce Comparative Examples A, B and C, respectively.
  • the amount of formic acid remaining for each Comparative Example is listed in the Table.
  • the Examples were prepared in the same manner as the control nonwoven web of the Comparative Examples, except 0.5 weight percent of antioxidant, Irganox 1098 (available from Ciba Specialty Chemicals Corp., Tarrytown, NY), based on weight of polymer was added to the spinning solution.
  • the resulting improved nonwoven web had a basis weight of 11.3 g/m 2 with fibers having an average fiber diameter of 350 nanometers.
  • the nonwoven web had a residual solvent content of 2783 ppm.
  • the improved nonwoven web was transported through a solvent stripping zone at a temperature of 180°C with hot air impinging the surface of the nonwoven web for residence times of 24, 48 and 240 seconds to produce Examples 1, 2 and 3, respectively.
  • the amount of formic acid remaining for each Example is listed in the Table.
  • Comparative Examples A, B and C show a reduction in the amount of formic acid with transportation through the stripping zone. Generally, one would expect a decrease in the amount of formic acid with increasing residence time in the zone stripping zone. However, it is observed that increasing the residence time from 48 to 240 seconds for Comparative Examples B and C respectively, increases the amount of formic acid. While not wishing to be bound by theory, it is believed that this increase in the amount of formic acid is due to degradation of the nylon to produce additional formic acid.
  • Examples 1, 2 and 3 also show a reduction in the amount of formic acid with transportation through the stripping zone.
  • the antioxidant containing nonwoven webs of the invention show a greater reduction in the amount of formic acid than the nonwoven webs without antioxidant.
  • Example 3 with a residence time of 240 seconds shows a continued reduction in the amount of formic acid from 48 seconds as compared to the increase in the amount of formic acid for the corresponding Comparative Examples.
  • this continued reduction in the amount of formic acid is due to protection of the nylon by the antioxidant to minimize or to prevent production of formic acid.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Artificial Filaments (AREA)
  • Nonwoven Fabrics (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
EP08846556.2A 2007-11-09 2008-11-07 Solvent stripping process ultilizing an antioxidant Active EP2207916B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US264307P 2007-11-09 2007-11-09
PCT/US2008/082764 WO2009062013A2 (en) 2007-11-09 2008-11-07 Solvent stripping process ultilizing an antioxidant

Publications (2)

Publication Number Publication Date
EP2207916A2 EP2207916A2 (en) 2010-07-21
EP2207916B1 true EP2207916B1 (en) 2017-03-01

Family

ID=40626446

Family Applications (1)

Application Number Title Priority Date Filing Date
EP08846556.2A Active EP2207916B1 (en) 2007-11-09 2008-11-07 Solvent stripping process ultilizing an antioxidant

Country Status (7)

Country Link
US (1) US20090178206A1 (ko)
EP (1) EP2207916B1 (ko)
JP (1) JP5476311B2 (ko)
KR (1) KR20100096146A (ko)
CN (1) CN101849045B (ko)
BR (1) BRPI0817372A2 (ko)
WO (1) WO2009062013A2 (ko)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2011503880A (ja) * 2007-11-09 2011-01-27 イー・アイ・デュポン・ドウ・ヌムール・アンド・カンパニー 改良された電気化学キャパシタ

Family Cites Families (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3607543A (en) * 1969-03-21 1971-09-21 Philip J Stevenson Process for forming lightweight nylon nonwoven web
US5573841A (en) * 1994-04-04 1996-11-12 Kimberly-Clark Corporation Hydraulically entangled, autogenous-bonding, nonwoven composite fabric
US5997789A (en) * 1997-03-31 1999-12-07 Toray Industries, Inc. Process of melt-spinning synthetic fiber
TW562889B (en) * 2000-07-31 2003-11-21 Sanyo Chemical Ind Ltd Lubricants for elastic fiber
US20020092423A1 (en) * 2000-09-05 2002-07-18 Gillingham Gary R. Methods for filtering air for a gas turbine system
US20020084178A1 (en) * 2000-12-19 2002-07-04 Nicast Corporation Ltd. Method and apparatus for manufacturing polymer fiber shells via electrospinning
US8129297B2 (en) * 2002-07-29 2012-03-06 E. I. Du Pont De Nemours And Company Method and apparatus for heating nonwoven webs
CN100575586C (zh) * 2003-06-30 2009-12-30 宝洁公司 纳米纤维网中的颗粒
US6969553B1 (en) * 2004-09-03 2005-11-29 Honeywell International Inc. Drawn gel-spun polyethylene yarns and process for drawing
US7846374B2 (en) * 2004-11-05 2010-12-07 E. I. Du Pont De Nemours And Company Blowing gases in electroblowing process
KR100665838B1 (ko) * 2004-12-01 2007-01-09 삼성전자주식회사 커패시터의 스토리지 전극과 그의 제조방법
US20060135020A1 (en) * 2004-12-17 2006-06-22 Weinberg Mark G Flash spun web containing sub-micron filaments and process for forming same
EP1746187A1 (en) * 2005-07-18 2007-01-24 DSM IP Assets B.V. Polyethylene multi-filament yarn
JP4653617B2 (ja) * 2005-09-28 2011-03-16 帝人株式会社 静電紡糸法により繊維構造体を製造する方法および装置

Non-Patent Citations (1)

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Also Published As

Publication number Publication date
WO2009062013A3 (en) 2009-07-16
JP2011503378A (ja) 2011-01-27
BRPI0817372A2 (pt) 2017-06-13
JP5476311B2 (ja) 2014-04-23
CN101849045A (zh) 2010-09-29
WO2009062013A2 (en) 2009-05-14
CN101849045B (zh) 2013-07-24
EP2207916A2 (en) 2010-07-21
US20090178206A1 (en) 2009-07-16
KR20100096146A (ko) 2010-09-01

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